Danfoss PCVD Bedienungsanleitung

Instructions

Pilot-controlled Pressure Reducer PCVD,

Pilot-controlled Safety Shut-oﬀ-valve PCVSAD

DN 100-250,PN16/25

English Page 2

Einbau-, Bedienungsanleitung

Hilfsgesteuerter Druckminderer PCVD,

Hilfsgesteuertes Sicherheitsabsperrventil (SAV) PCVSAD

DN 100-250,PN16/25

Deutsch Seite 16

Instructions PCVD, PCVSAD

2 | © Danfoss | 2016.05 VI.JA.C3.5B

1 Safety Notes .......................................................3

2 Deﬁnition of Application .............................3

3 Description...........................................................4

3.1 Construction ......................................................... 4

3.2 Mode of Operation ............................................ 4

4 Technical Data ................................................... 4

5 Scope of Delivery.............................................. 5

6 Assembly .............................................................. 6

6.1 Prior to Assembly ................................................ 6

6.2 Installation Position ........................................... 6

6.3 When Installing observe ................................... 6

6.4 Impulse Tube Installation ................................. 6

6.5 Insulation ............................................................... 6

6.6 Installation Scheme ............................................ 7

6.7 Assembly Drawings, Dimensions ................. 8

7 Start-up................................................................10

7.1 Required Static Pressure, Pressure

Diﬀerence ............................................................10

7.2 Leak and Pressure Tests ..................................10

7.3 Filling the System ..............................................10

7.4 Start-up .................................................................10

7.5 Putting out of Operation ...............................10

7.6 Adjustment of the Setpoint .......................... 11

7.7 Sealing .................................................................. 11

7.8 Function Test ...................................................... 11

8 Trouble Shooting ...........................................12

8.1 Fault, Possible Cause, Remedy ..................... 12

8.2 Diaphragm Break of

the Controller SAVD ......................................... 12

9 Replacement of Valve,

Actuator, Trim ..................................................13

9.1 Dismounting and Mounting Actuator

and Valve of the Valve Unit ........................... 13

9.2 Replacement of Trim Valve VFG 2 ............... 14

9.3 Dismounting,

Mounting Actuator AVD, SAVD ....................14

9.4 Replacement of

Trim Valve AVD, SAVD ...................................... 15

Table of Contents

Instructions PCVD, PCVSAD

VI.JA.C3.5B

MAINTENANCE

FREE

1 Safety Notes

2 Deﬁnition of

Application

The controller is used for ﬂow rate limitation of

water for heating, district heating and cooling

systems.

The admissible medium temperatures depend

on the design and comprise 5-150 °C,

5-200 °C.

The technical data on the rating plates deter-

mine the use.

Prior to assembly and

commissioning to avoid injury

of persons and damages of the

devices, it is absolutely

necessary to carefully read and

observe these instructions.

Necessary assembly, start-up, and maintenance

work must be performed only by qualiﬁed,

trained and authorized personnel.

Prior to assembly and maintenance work on the

controller, the system must be:

depressurized,

cooled down,

emptied and

cleaned.

Please comply with the instructions of the

system manufacturer or system operator.

Instructions PCVD, PCVSAD

4 | © Danfoss | 2016.05 VI.JA.C3.5B

Pilot controller AVDThrottling element

Valve Unit PCV-VFG2

Throttling valve

hrottling valve

only DN150-250

3 Description 3.1 Construction

3.2 Mode of Operation

The control unit consists of the PCV-VFG2 valve

unit, installed in the main pipe, and the pressure

controller AVD or safety shut-oﬀ-valve SAVD

installed as pilot controller in the bypass. In the

bypass line, a throttle element is installed in front

of the pilot controllers.

As a pressure reducer, the controller keeps the

pressure behind the controller unit in accordance

with the preset setpoint on a constant level.

As a safety shut-oﬀ valve, the controller

guarantees that the pressure is not exceeded. If

the controller diaphragm is damaged, the valve

is closed via the second diaphragm.

The valve and the pilot valves are pressure-

balanced.

The setpoint for the pressure is adjusted by

pre-stressing the setpoint spring of the pilot

controller.

Valve unit PCV-VFG 2

The valve unit in the main pipe is opening on

rising pressure. The pilot controllers in the

bypass line are closing on rising pressure.

In case of small ﬂow rates, the valve in the main

pipe remains closed through the pressure spring

in the actuator of the valve unit. The pressure is

exclusively controlled by the pilot controller.

If the ﬂow rate in the bypass is increased, the

pressure in the throttle element (Venturi nozzle)

decreases.

The reduced pressure acts through an impulse

tube upon the lower chamber of the actuator

of the valve unit. The main valve is thus opened

shock-free and continuously.

If the ﬂow rate is reduced, the pressure in the

throttle element raises and the main valve closes.

This sequential switching guarantees an

operation free of vibrations and a small control

deviation over a wide positioning range.

4 Technical Data

Technical data, see rating plates and the PCV

data sheet.

Instructions PCVD, PCVSAD

VI.JA.C3.5B

5 Scope of Delivery

DN 100-125

Assembly kit valve unit PCV-VFG 2 Pilot controller AVD DN 25

AVD

Cu pipe Ø 6 × 1 × 1500 mm

Cu pipe Ø 10 × 1 × 3000 mm

Throttling element

DN 150-250

Assembly kit valve unit PCV-VFG 2 Pilot controller AVD DN 40

Throttling element

Cu pipe Ø 6 × 1 × 1500 mm

Cu pipe Ø 10 × 1 × 3000 mm

SAVD

AVD SAVD

Instructions PCVD, PCVSAD

6 | © Danfoss | 2016.05 VI.JA.C3.5B

pin only

weld

do NOT

weld

6 Assembly 6.1 Prior to Assembly:

Depressurized system before

any assembly work !

CAUTION!

• Clean pipeline system.

• Install strainer in front of the controller.

• Install shut-oﬀ units in front of and behind

the controller.

6.2 Installation Position

• Installation is only permitted in horizontal

pipelines with the actuators hanging in a

downward position.

6.3 When installing observe:

• Observe direction of ﬂow.

• Design with welded ends:

• Loads on the valve body and the throttle

element by the pipes are not permitted.

6.4 Impulse Tube Installation

1. See installation scheme, section 6.6.

2. For CU pipes Ø 10 × 0.8, insert sockets 1on

both sides.

3. Care for correct position of the cutting

rings 2.

6.5 Insulation

The diaphragm actuators must not be insulated

when insulating system parts.

4. Press impulse tube into the threaded ﬁtting

up to its stop.

5. Tighten union nut, torque 40 Nm

6. Dismount again and check the position of

the cutting rings.

Instructions PCVD, PCVSAD

VI.JA.C3.5B

Shu

t-off valve

CU pipe Ø 6 × 1

Valve unit PCV - VFG 2

Throttle valve

Throttling element

Throttle valve

(DN 150-250 only)

CU pipe Ø 10 × 1

Pilot controller AVD

lay impulse tube during mounting

o not install a

shut

-oﬀ valve her.

But if you do s

is absolutely

necessar

secure against

unauthorized

closing

CU pipe Ø 6 × 1

Valve unit PCV - VFG

Throttle valve

Throttling element

Throttle valve

(DN 150-250 only)

CU pipe Ø 10 × 1

Pilot controller SAVD

lay impulse tube during mounting

6.6 Installation Scheme

Installation in the Return Line

Installation in the Supply Line

Instructions PCVD, PCVSAD

8 | © Danfoss | 2016.05 VI.JA.C3.5B

Dismount impulse tube

- Unscrew threaded fittings at the

valve and at the actuator

- Close opening at the valve

with a stopper (see assembly kit

order No. 003G1599)

Cu pipe Ø 10 × 1

Lay when assembling.

Install impulse tubes

laterally because of dir

pipe Ø 6 × 1,

when laying

use the assembly

kit

order No

. 003G1599

Valve unit PCV - VFG 2

DN 25: pipe Ø 33,7 × 3,2

terial: ST 35.8

(not par

t of the delivery)

Pilot controller AVD

DN 25 SW 50

Throttling element

these parts are

not in the scope of delivery

6.7 Assembly Drawings, Dimensions

DN 100-125

Instructions PCVD, PCVSAD

VI.JA.C3.5B

Dismount impulse tube

- Unscrew threaded fittings at the

valve and at the actuator

- Close opening at the valve with a

stopper (see assembly kit order

No. 003G1599)

Cu pipe Ø 10 × 1

Lay when assembling.

Install impulse tubes

laterally because of dirt

pipe Ø 6 × 1,

when laying

use the assembly

kit

order No

.003G1599

DN 40: pipe Ø 48,3 × 3,2

terial: ST 35.8

(not par

t of the delivery)

these parts are

not in the scope of delivery

DN 150-250

Dimensions

Nominal diameter DN 100 125 150 200 250

350 400 480 600 730

H1 530 530 619 647 697

H2 -174 229 254

D2 263 380

D1 250 350 385 500

B200 210 310 336 412

A ≥ 290 320 350 410

Instructions PCVD, PCVSAD

10 | © Danfoss | 2016.05 VI.JA.C3.5B

p2 p1

910

7 Start-up 7.1 Required Static Pressure, Pressure

Diﬀerence

For a proper functioning, a minimum pressure

diﬀerence of p1 − p2 ≥ 0.5 bar is required.

The static pressure p1 in front of the controller

must not fall below 1.5 bar (excess pressure).

Non-observance may lead to cavitation and

damages in the throttling element 1.

7.3 Filling the System

Note:

The controller 6is closed when no pressure is

applied and only opens with a deﬁned ﬂow in the

bypass.

The pilot controllers 7are closing on rising pressure.

7.2 Leak and Pressure Tests

To avoid too high pressures at

the diaphragm actuators, the

following should be observed

prior to any pressure tests:

Actuator of valve unit:

The admissible operating excess pressure in the

actuator 2is 15 bar 1). For higher pressures, you

must:

• Remove the impulse tube 3

The admissible operating excess pressure in the

actuator 4is 25 bar 1). For higher pressures, you

must:

• Remove the impulse tubes 5at the actuator

and close the connections with a stopper

• Prior to any leak or pressure test, the

instructions in section 7.3 must be complied

with.

1) Pre-condition: Same pressure on both sides of the diaphragm.

If the pressure load is one-sided, the (+)diaphragm chamber

may have an excess pressure of 1 bar in comparison to the (-)

diaphragm chamber.

Procedure

1. Open shut-oﬀ valves 8that possibly exist in

the impulse tubes.

2. Slowly open shut-oﬀ units ﬁrst in the return

ﬂow 9and then in the supply ﬂow 10.

7.4 Start-up

During starting-up the ﬁlled system, open the

units in the same sequence as described in

section 7.3.

7.5 Putting out of operation

When putting the system out of operation, ﬁrst

close the shut-oﬀ units in the supply ﬂow and

then those of the return ﬂow.

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